Monitoring chemicals and gases along pipes, valves and flanges

ABSTRACT

Detection and real-time reporting (via wireless to a remote receiver) of the release of harmful or otherwise unwanted chemicals or chemicals of corrosion into the environment and, more particularly, the undesired release of such chemicals from pipelines, supporting energy/electric/heating/cooling/storage/distribution infrastructure, refineries, chemical plants, factories, processing and manufacturing plants and equipment, storage tanks, engines, containers and the like. One or more detection devices can be placed nearby potential areas where leaks occur, or anywhere monitoring for leaks is desired. In some embodiments, the detection devices are integrated into components for monitoring said component for unwanted emissions.

CROSS REFERENCE TO RELATED PATENTS AND APPLICATIONS

The present application is a continuation of currently pending U.S.patent application Ser. No. 16/696,136, filed Nov. 26, 2019, whichapplication is a continuation of U.S. patent application Ser. No.15/914,025, filed Mar. 7, 2018, now U.S. Pat. No. 10,490,053, whichapplication is a continuation in part of patent application Ser. No.15/891,410, filed on Feb. 8, 2018, now U.S. Pat. No. 10,395,503, whichis a continuation of U.S. patent application Ser. No. 15/235,981, filedAug. 12, 2016, now U.S. Pat. No. 9,922,525, which application claims thebenefit of U.S. Provisional Patent Application Ser. No. 62/297,385,filed Feb. 19, 2016, U.S. Provisional Patent Application Ser. No.62/205,012, filed Aug. 14, 2015, and U.S. Provisional Patent ApplicationSer. No. 62/468,072, filed Mar. 7, 2017, which applications are herebyincorporated by reference.

FIELD

The present exemplary embodiment relates to systems and methods fordetecting chemicals or gasses including chemicals produced by corrosion.It finds particular application in conjunction with detecting chemicalsigns of corrosion or leaks from pipelines, valves, pressure fittings,pump, plugs, gauges, connectors, compressors, open-ended lines, pipejoints, couplings and other fluid transmission components and storagecontainers etc., and will be described with particular referencethereto. However, it is to be appreciated that the present exemplaryembodiment is also amenable to other like applications.

BACKGROUND

The Environmental Protection Agency (EPA) has determined that leakingequipment, such as valves, pumps, and connectors, are the largest sourceof emissions of volatile organic compounds (VOCs) and volatile hazardousair pollutants (VHAPs) from petroleum refineries and chemicalmanufacturing facilities. A typical refinery or chemical plant can emit600-700 tons per year of VOCs from leaking equipment. Accordingly, Leakdetection and repair (LDAR) is an important part of reducingenvironmental contamination from such facilities.

The EPA has set forth standards and guidance on determining such leaksof VOCs and HAPs through a framework known as Method 21. This Methodapplies to, but is not limited to, valves, flanges and otherconnections, pumps and compressors, pressure relief devices, processdrains, open-ended valves, pump and compressor seal system degassingvents, accumulator vessel vents, agitator seals, and access door seals.The Method establishes the type of instrumentation, equipment andsupplies that can be used to monitor leaks; it also definesconcentration standards for measuring emissions by equipment type; itdefines how samples should be collected, tested and reported; it alsoestablishes a protocol for quality control as well as criteria forauditing facilities and how they conduct LDAR.

LDAR for chemical processing plants, such as refineries, is typicallyperformed by trained personnel. The trained personnel are tasked withphysically inspecting and sampling a wide variety of valves, pipeflanges, compressors, etc. for leakage on a periodic basis. Thistypically includes taking measurements with a handheld chemicaldetector. Current LDAR programs are labor intensive, time consuming, andhave been found by the Environmental Protection Agency (EPA) to rarelybe properly implemented by plant operators. The proper implementation issomething that the agency aggressively pursues with its oversight alongwith other state and local regulators.

The failure of plant operators to properly implement a LDAR program, inmany cases, is due primarily to the overwhelming expense, record-keepingand complexity such programs require. The expense comes not only fromthe physical labor involved with visiting and testing each component forleakage, but with keeping track of acceptable leakage rates for the widevariety of components and varying standards that exist in a typicalplant, such as a refinery.

For example, each type of valve may have its own acceptable leakagethreshold. For each given type of valve, each size of that type of valvemay have a different acceptable leakage threshold. Further, newer valvesmay have different acceptable leakage thresholds than older versions ofthe same valve. The same challenges exist with other components such ascompressors, connectors, sampling ports, etc. Thus, the record keepingrequired to track all components and their respective acceptable leakagethresholds presents a significant challenge as plant components arereplaced and/or updated. Leakage thresholds also depend on the type ofanalyzers used and their respective detection capability. As a result,matching analyzing equipment standards with those for which they aremonitoring is extremely challenging when dealing with thousands and insome cases millions of components.

Therefore, the trained personnel must not only sample each component,but must also determine the acceptable leakage threshold for the sampledcomponent based on documented standards and best practices. Asignificant risk of error is misidentification of a given component(and/or acceptable leakage threshold). Risk of error also exists whensampling, as human operators may misuse the equipment or the equipmentmay not be calibrated properly.

U.S. Pat. No. 7,176,793 discloses a detection device in the form of astrip for use in an enclosed container. The detection strip includessensors of macro, meso or nanosize, all of which are referred to asnanosensors, for detecting materials that are harmful to human beingswithin an enclosed container and for transmitting a correspondingresonance frequency. One or more detection strips are initially placedwithin a container, depending on the size of the container. Other typesof nanosensors including those that detect temperature, humidity,location and other conditions can also be part of the sensor array. Thedetection devices are designed to send off specific resonant frequencysignals which can be detected by voltage changes and/or current changeswhich are correlated to any harmful material detected within thecontainer. In some applications, sensors can be located in open air andcan be configured to receive and sample a forced air flow. A serialnumber computer chip is provided for specifically identifying thedetection device and transmitting a corresponding resonance frequency,which allows the container to be identified. A power source is providedfor operating the detection strip. A hand-held or stationary monitor isprovided for monitoring the container for any signals given off from thedetection strips within the container. The detection devices aredesigned to give off a predetermined amount of background signal. Inconsequence, if no such signals are received, the container is highlysuspect as being tampered with, allowing such a container to be quicklyremoved and its contents examined.

SUMMARY

Aspects of the present disclosure are directed to methods, processes,tactics, systems and devices for transforming the manual LDAR process toan automated and digitized LDAR process that is more effective at alower cost, thus reducing pollution while saving plant operators money.In one embodiment, aspects of the present disclosure combine “digitaltransformation” and the Internet of Things (IoT) or Machine to MachineCommunication. The present disclosure allows the core task of monitoringleaks and tracking progress in that task, but also collects data that ishighly valuable to broader business operations, specifically on-goingmaintenance and repair. The data can go as far as becoming a criticalinput to refinery operations KPIs that are disclosed to the public. Thepurpose of showing in KPIs would be two fold: i) provide an indicationof how well a company manages its programs associated with public“externalities” (i.e. emissions of VOCs and HAPs) ii) provide anindication how the proper and efficient management of those programslead to more efficient production, reducing product losses throughunwanted emissions and the level of safety for facility workers andinfrastructure operators. Insight into how a publicly traded company ishandling leak detection and repair (LDAR) will provide greater evidenceto regulating agencies and bodies and may ultimately lead to avoidingenforcement actions and fines.

Aspects of the present disclosure relate generally to the detection andreal-time reporting (via wireless to a remote receiver) of the releaseof harmful or otherwise unwanted chemicals or chemicals of corrosioninto the environment and, more particularly, the undesired release ofsuch chemicals from pipelines, supportingenergy/electric/heating/cooling/storage/distribution infrastructure,refineries, chemical plants, factories, processing and manufacturingplants and equipment, storage tanks, engines, containers and the like.The present disclosure sets forth one or more detection devices whichare placed nearby potential areas where leaks occur, or anywheremonitoring for leaks is desired. In some embodiments, the detectiondevices are integrated into components for monitoring said component forunwanted emissions. The detection devices are designed not only todetect the presence of a particular chemical, but also its level (e.g.in parts per million, parts per billion, or parts per trillion, etc.).Detecting levels of emissions of unwanted chemicals or gases will helpguide operators' planning of maintenance and repair as well as broaderLDAR activity.

In essence, the present disclosure sets forth a system and method forautomated detection, processing and/or decision making associated withchemicals of corrosion or leaks of harmful chemicals at refineries,chemical plants and/or any other facilities having infrastructure pronewith leak potential. The automated detection is based on generating datathat previously could not be generated by manual approach using anetwork of sensors, and processing that data for accurate and real-timeautomated decision making related to a specific set of defined criteriathat can be programmed to the device.

The new automated process in accordance with the present disclosuredisplaces and/or augments existing manual LDAR techniques whereby humanoperators are required to test hundreds of thousands or millions ofareas prone to leaks using hand-held samplers as shown, (e.g., see, forexample, FIG. 20 ). Each piece of equipment has a different standard andthe standards vary by the model and brand of equipment. The presentdisclosure facilitates automated sampling that not only detects whethera piece of equipment is emitting past a minimum baseline concentrationand a maximum standard, but also the varying levels between, which arelikely to be a result of utilization and overall plant productivity.This type of reporting generates useful data for not only measuringplant utilization level and the stress being placed on related componentequipment, but also shows how that level or operation contributes tolevels of unwanted emissions.

Aspects of the disclosure can provide managers of infrastructure andother facilities involving harmful or other chemicals informationregarding when, where and at what level the harmful or other chemicalsare present. A network of remote sensors powered by batteries, solarpower or by electromagnetic energy via an antenna from the wirelessnetwork can communicate wirelessly with hand-held devices and/orterminal stations to allow for real-time leak detection and analysis,planning and decision making. Open source stations for receiving,processing and analyzing sensor data are also contemplated.

This disclosure further sets forth methods and devices for fixating orotherwise mounting sensors (e.g., nano-tube sensors) to or withinproximity to components prone to corrode or leak throughout pipelineinfrastructures such as refineries, factories, chemical plants,processing and manufacturing facilities and water treatment facilities.In some embodiments, the sensors are integrated into with equipment andcomponents prone to unwanted emissions or leaks. The present disclosurefacilitates the detection of harmful or other chemicals that would provedangerous or undesirable to human operators and broader facilityoperations, the environment, humans and more broadly businessoperations.

The system can include flexible strips, magnetic, adhesive,hook-and-loop or similar structures capable of permanent or temporaryfastening to a pipe, flange, valve or other structure (e.g., a weld).The flexible strips are embedded with one or more of nano-sensors, apower source (including a lithium ion (or other) battery and/or poweredby electromagnetic energy via an antenna from the wireless networkand/or solar cell capabilities, solar power being especially useful forsensors in remote areas such as gas pipelines and hard to reach areas offactories where replacement due to failing power source would bechallenging), humidity and temperature sensors (can be used to activelycalibrate the passive sensors due to the environment in which the sensoris operating) and circuitry to communicate wirelessly with hand-helddevices and terminals. The sensors are placed nearby sources ofpotential corrosion or leaks (e.g., unwanted emissions) including, butnot limited to: pumps, valves, connectors, sampling connections,compressors, pressure relief devices, open-ended lines, welds, pipejoints and couplings, plugs, gauges, tanks, engines, storage containersand other energy infrastructure, plant and equipment carrying harmful orexpensive gases (e.g., gases with monetary value or core to businessmodel) and/or chemicals where leaks or emissions are not wanted, etc.

Depending on the particular application, the sensors can be embedded ineither a flexible strip, foam or sponge or other material that can bewrapped in durable fabric capable of withstanding extreme temperatures,humidity and other harsh conditions and fastened to a pipe flange usinghook-and-loop fasteners, elastic, pins, magnets, insulation, neoprene,polyethylene foam, advanced composites and plastics, rubber, fiberglassacrylic industrial adhesive tape, or other securements. The durable andtemperature resistant fabric can have a small power source light and/orother indicators visible when the system is installed to indicatewhether the sensor is functioning (e.g., sensor self-reports its stateof operability) or to indicate other functions/operations. These samefunctions can be transmitted via the wireless circuitry to a wirelessreceiver or smart phone, wearable device, etc.

A similar approach can be taken for valves, pressure relief devices,welds and pipe joints. For valves, a bonnet of plastic or other suitablematerial (e.g., durable fabric including nano-fabrics made of grapheneor other particles of the nano scale) with elastic can be stretched overthe valve body and/or actuation member (e.g., knob, lever, handle,electromechanical actuator, etc.). In some examples, the bonnet materialitself can be elastic and made of material with embedded sensorsincluding nano-fabrics. In other examples, the bonnet material may besubstantially inelastic and a separate elastic member can be provided toallow an opening of the bonnet to be stretched over structures such asvalves, for example. The bonnet material can support the sensors and ora light or other indicator that indicates whether the sensors arefunctioning.

The sensor component can use nano-particle, doped nano-tube, nano-tube,nanowire or other nano-type designs including nanofilm, nanocages,nanochains, nanocomposites, nanofabrics, nanofibers, nanoflakes,nanomesh, polymers, graphene or other carbon form of the nanoscale tomonitor for chemical leaks along pipes, valves, flanges, welds or otherareas for the purposes of safety monitoring such as in refineries,chemical plants, exhaust systems, engines, rocket motors, other pipes,fittings and connections and storage tanks, for example. In someexamples, Microelectrochemical systems (MEMS) and/orNanoelectromechanical systems (NEMS) can be used. In some examples,quantum dots or graphene quantum dots can be used. In still otherexamples, electrochemical, electrochemical amperometric, metal oxidesemiconductor, infrared sensor (nondispersive), thermal sensor(pellitor), photoionization (PID), chemoresistors, graphene, hybrid andnanostructures, Quartz Microbalance, and/or field-effect transistor(FET) type devices can be used.

The device can consist of a nano sensor or array of nano sensors thatare connected to a potentiostat, amplifier, analog to digital converterADC, an analyzer microprocessor (CPU) and a memory that containsalgorithms, which can be downloaded from a central source, that allowthe sensors to differentiate multiple chemicals and gases. The sensorscommunicate with the CPU/memory and then report their findings via adata-link, standard wireless connection, near-field, bluetooth or otherwireless connection which can be encrypted, if desired.

Each sensor or array of sensors can have an exclusive encrypted serialnumber which is reported along with the sensing data to a common datacollector, which can be a wireless device or other centralizedcollector.

The sensor or array of sensors also can contain additional sensors fortemperature, humidity and/or location, such as a GPS locator circuitsuch that a refinery having hundreds or thousands or millions of sensorscan be displayed on screen in a multi-dimensional picture of the entirerefinery's potential leak areas. The sensors can report the level ofemission and compare the level to an established baseline of a newlyinstalled piece of equipment (e.g., to the standard established by theLDAR Program by which emission cannot exceed without requiringreplacement). Analytics can be used to display the level as well asother plant and equipment utilization indicators like pipe pressure,temperature, vibration and other metrics that provide an indication ofutilization and the stress the level of utilization poses for theinfrastructure. All of these metrics, particularly the leak detectionmetric, help operators plan maintenance and repair for optimalproduction and mitigate enforcement actions from regulators.

The sensor or sensor array and all electronics can be embedded in amagnetic disc, elastic covering or other shape that can be directlyaffixed or built directly into or in a compartment of the flange, pipeor area to be monitored for leaks.

In another example, the sensor or sensor array and electronics areembedded in a non-metallic, non-magnetic structure that can be affixedto the area to be monitored by adhesive, strapping or elastic. Otherpossibilities exist including using a temperature resistant heavy dutywrap with industrial Velcro or other fastener. This approach combinesindustrial grade composites resistant to extreme temperature andconditions. Another approach includes the use of an industrial gradenanofabric with embedded sensors. The fabric is fastened using a drawstring. Similarly, the sensors can be enclosed in a durable, extremecondition-resistant wrap, but breathable bag that allows the sensors tooperate without causing corrosion. A standard adjustable elastic flangecovering packed with the sensor strips can be deployed. In anotherembodiment, a casing made of advanced composites or other materialssuitable for such application can be secured around the pipe flange andsecured with a standard clasp lock.

The sensor or sensor array can be replaceable within the overall sensordevice. The entire device can have a red (or other color) LED light thatilluminates when the entire sensor array needs to be replaced. The samelight can blink when just the sensor array within the device needs to bereplaced. These same two signals can also be sent by wireless to awireless device or central monitoring device. The unit can be powered byeither a small battery or directly via wireless energy via an antenna orby solar energy.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary chemical processing plantincluding a system in accordance with the present disclosure;

FIG. 2 is a schematic view of a portion of the plant of FIG. 1illustrating various components and sensors for detecting leakage;

FIG. 3 is a side view of an exemplary pipe flange having a sensor inaccordance with the present disclosure;

FIG. 4A illustrates an exemplary sensor array in accordance with thepresent disclosure;

FIG. 4B illustrates a single sensor in accordance with the presentdisclosure;

FIG. 5 is a schematic illustration of a sensor unit and remotemonitoring device in accordance with the present disclosure;

FIG. 6 is a cross-sectional view of a first strap attach assembly inaccordance with the present disclosure;

FIG. 7 is a cross-sectional view of a second strap attach assembly inaccordance with the present disclosure;

FIG. 8 is a cross-sectional view of a third strap attach assembly inaccordance with the present disclosure;

FIG. 9 is a perspective view of an exemplary monitoring system in theform of a flange band in accordance with the present disclosure;

FIG. 10 is a perspective view of an exemplary system in accordance withthe present disclosure.

FIG. 11 is a side elevation view of an exemplary flange band inaccordance with the present disclosure;

FIG. 12 is a side elevation view of an exemplary flange band inaccordance with the present disclosure;

FIG. 13 is a side elevation view of an exemplary flange band inaccordance with the present disclosure;

FIG. 14 is a side elevation view of an exemplary flange band inaccordance with the present disclosure;

FIG. 15 is a side elevation view of an exemplary flange band inaccordance with the present disclosure;

FIG. 16 is a perspective view of an attachment device in accordance withthe present disclosure in the form of a bonnet for securing a sensor toa valve component;

FIG. 17 is a perspective view of yet another attachment device inaccordance with the present disclosure for securing a sensor to a targetcomponent;

FIG. 18 is a perspective view of still another attachment device inaccordance with the present disclosure for securing a sensor to a targetcomponent;

FIG. 19 is a perspective view of an independent mount for a sensor inaccordance with the present disclosure; and

FIG. 20 illustrates a prior art method of testing a target component forunwanted emissions.

DETAILED DESCRIPTION

With reference to FIG. 1 , an exemplary refinery R (or other facility)is illustrated with a plurality of sensors S (shown as small black andgrey circles) mounted to various components in accordance with thepresent disclosure. The sensors S are connected together with one ormore receivers for receiving data generated by the sensors S. As will beappreciated, the network may be a mesh network, star network, or anyother type of network. Each sensor S is adapted to transmit datarelating to one or more of the presence and/or concentration of one ormore chemicals, sensor status/health, power supply condition, etc. Eachsensor can include an indicator for indicating proper function, such asa led light or the like. The chemicals can be liquid or gaseouschemicals.

FIG. 2 schematically illustrates a fresh air inlet portion of therefinery R. It will be appreciated, however, that the principlesdisclosed in connection with the fresh air inlet portion of the refineryR are applicable to virtually any other portion of the refinery. Thefresh air inlet generally comprises a plurality of components includinga gauge cock A, a motorized valve B, a flanged elbow C, a pressurereadout D, a locked valve E, a plug F, an expansion joint G, aneccentric reducer H, a turbine I and a number of pipe connectors J.

Many, if not all, of the components of FIG. 2 are monitored for unwantedemissions by a plurality of sensors S positioned in proximity to thecomponents. The sensors S are typically mounted directly to thecomponents via various mounting/attaching mechanisms (examples describedbelow) that support the sensors S in a suitable location for sampling.In some applications, the sensors can be supported by structure adjacentto the component. The sensors can also be built directly into thecomponents or in a compartment of the component being monitored foremission.

Turning to FIG. 3 , an example pipe P and pipe flange F (e.g., pipeconnector J, as shown in FIG. 2 ) are illustrated including an exemplarysensor S shown schematically in proximity thereto in accordance with thepresent disclosure. The sensor S can be integrated with the flange F(e.g., provided as part of the flange F by the flange manufacturer) orsecured to the flange F in a variety of manners. The pipe P and flange Fare exemplary in nature, and it will be appreciated that the sensor Scan be integrated into/attached to a wide range of fluidtransport/transmission/storage components including, but not limited to,pumps, valves, connectors, sampling connections, compressors, pressurerelief devices, open-ended lines, welds, pipe joints, pressure readouts,plugs, gauges, turbines and couplings, containers or enclosures wrappedaround joints and valves, etc., without departing from the scope of thisdisclosure. The sensor S can be secured to the pipe and/or pipe flangein a variety of manners, including the manners set forth herein. Themanner in which a sensor or sensor array is secured depends at least inpart on the equipment type and the conditions by which the equipment isintended to operate.

With reference to FIG. 4A, an exemplary sensor strip (array) SS isillustrated. The sensor strip SS includes a plurality of individualsensor units SU, as shown in detail in FIG. 4B. Each sensor unit SUincludes a substrate (e.g., flexible, thin film, thick film and/or othermaterials appropriate for given application) 2 supporting a referenceelectrode 3, a working electrode 4, and a counter electrode 5.Conducting pads 6 are provided for coupling the electrodes to associatedcircuitry (e.g., processor, communication circuitry, etc.).

In FIG. 5 , a sensor S is schematically shown including a sensor stripSS. The sensor S generally includes a monitor/detector component 20,which includes a plurality of sensor units SU. As will be appreciated,any number of sensor units SU can be provided, and each sensor unit SUcan be configured to detect a specific chemical. One monitor/detectorcomponent that is particularly well-suited for purposes of the presentdisclosure is set forth in U.S. Pat. No. 8,629,770 to Hummer et al. andU.S. Pat. No. 7,176,793 to Hummer, both of which are incorporated hereinby reference in their entireties. Other types of monitor/detectorcomponents can also be used in accordance with the present disclosure.

The sensor S further includes communication circuitry 22 and a powersource 24. The communication circuitry 22, in one embodiment, includesat least one of a near field communication device, Bluetoothcommunication device, WIFI communication device, or any other suitablecommunication circuitry for establishing communications with a remoteprocessing device 12. The power source 24 can be a power supply such asa battery (lithium or other). In some cases the battery will be printedinto the sensor along with the circuitry and electronics. In otherembodiments, the power source 24 can be an antenna configured to receiveenergy wirelessly and supply the received energy to one or both of themonitor/detector component 20 and/or communication circuitry 22 suchthat no onboard battery is required for operation of the monitor system16. Solar cells can also be used to provide power. An active or passiveair flow induction device 26 can be provided for ensuring adequate andor continuous flow of air to the monitor/detector component 20. Suchdevices can include fans, micropumps, louvers, vents etc. An activeinduction device can be separately replaceable within the system and caninclude its own power supply. Alternatively, an active induction devicecan be configured to receive power from power supply 24 (or from powersupply solar cells).

It should be appreciated that the monitor/detector component 20 cancomprise a plurality of sensors strips SS. The sensor units SU and orstrips SS can be individually replaceable or can be replaced as a unit.Replacement of the sensor units SU and/or strips SS may be necessary dueto sensor degradation. In other situations, a user may wish to detectcertain chemicals and will choose which sensors to install in thesystem. In one embodiment, the entire sensor S is replaceable as a unit.

The sensor units SU may detect a wide range ofchemicals/materials/gasses. In the exemplary embodiment, the sensorunits SS are configured to detect volatile organic compounds (VOCs) suchas benzene, zylene and toluene for example, or any other chemical whereleakage into the atmosphere or elsewhere is undesirable. It will beappreciated that the sensor S is configured to communicate with theremote processing device 12. That is, the sensor S collects data andtransmits or otherwise shares the collected data with the remoteprocessing device 12 for processing. The remote processing device 12 ofthe illustrated embodiment includes a processor 30, a memory 32, acommunication circuitry 34, and a power source 36. It will beappreciated that the remote processing device 12 can include a widevariety of additional components as is conventional. Such additionalcomponents can include a display device, input device, various sensors,various antennas, etc. In some examples, the processor and memory can beonboard the sensor S. In one embodiment, precision ink-jet printingand/or screen printing is used to produce all or part of the sensor S.

Data collected by the monitor/detector component 20 is transmitted viacommunication circuitry 22 to communication circuitry 34 of the remoteprocessing device 12. Other data, such as sensor state, status,performance data, and the like can also be transmitted to the remoteprocessing device 12. Any suitable manner of transmitting the data fromthe sensor S to the remote processing device 12 can be employed.

The data collected and transmitted by the sensor S is then processed bythe remote processing device 12 to detect one or more chemicals inaccordance with one or more methods set forth in U.S. Pat. No. 8,629,770to Hummer et al. and U.S. Pat. No. 7,176,793 to Hummer. To this end,suitable software for analyzing the data is stored in memory 32 of theremote processing device 12. Other detection and/or analyzing methodsand techniques may also be used in conjunction with aspects of thepresent disclosure.

It will be appreciated that in some embodiments, the sensor S caninclude onboard processing and memory for performing onboard processingof the data generated by the sensor units SU. In such case, the sensor Ssoftware can be programmed and reprogrammed remotely to adjust sensorbaselines (minimum detection level) and thresholds (maximum detectionlevel). This remote reprogramming feature allows the system to evolvewith the fast pace changes in standards, which are based on installedcomponents and the technique by which the emissions are sampled todetermine leaks and levels of unwanted emissions.

In one embodiment, the software stored in memory 32 can be in the formof an application, or “app”, that is downloaded from an app store or thelike. The app can be provided with various “signatures” of chemicals.The signatures can be compared to the data to determine whether thechemical signature was detected by the sensor system S. The app can beconfigured to be automatically updated with new signatures as the needto detect particular chemicals arise. That is, it is possible to providenew and/or additional chemical signatures for the app to check againstthe data to detect specific chemicals without changing the sensors oradding specific new sensors.

The app can further include features such as adjustable thresholds. Forexample, for some chemicals that are routinely present in certainamounts and/or not generally considered dangerous below certain levels,the application can be configured to detect or trigger an alarm when athreshold amount is met or exceeded. For some chemicals which areconsidered dangerous in any amount, the thresholds would not generallybe adjustable. It will be appreciated that the application's underlyingsoftware can be reprogrammed to adhere to changing objectives (i.e.changes in levels of emissions, changes in operational tempo or capacityand new threats, etc.) For example, in some instances the level ofemissions is tied to utilization and stress on the system. A systemrunning at its highest capability may have increased leakage and mayexceed the threshold amount. If operators choose to run systems atmaximum levels, the sensor thresholds can be temporarily increased untila lower operational tempo resumes.

In some embodiments, the functioning sensor can be used to set theminimum baseline leakage under normal operating conditions. To this end,the sensor can be calibrated under normal operating conditions todetermine a minimum baseline leakage, as some leakage is likely presentand detectable under normal operating conditions. This baseline leakagevalue can be used to avoid/mitigate false alarms by establishing anormal operating leakage.

The app can be further configured to, once a chemical is detected, sharethe detection information. For example, the application can beconfigured to use the communication circuitry 34 to broadcast an alert(or generate a notification) via any suitable communications network(e.g., WIFI, NFC, Bluetooth, cell, etc.). The alert may be directly sentto other, for example, personal communication devices of maintenancepersonnel in the area, or may be sent to a server (or through a network)and then on to devices within a range of a given location. In oneexample, when an alert is triggered by the automatic sensor S, anoperator with a hand-held device (e.g., a handheld device with sensingcapabilities) can be dispatched to verify that the component is indeedemitting past the maximum threshold. In some examples, the alarminformation can also be shared immediately with regulators or governingbodies that oversee the LDAR programs, and the governing bodies mayoffer incentives to the plant owner for sharing such information. Theinformation could also be shared in an open source dashboard for thepublic to consume through analytics.

Providing the sensor S as a separate component selectively attachable toa fluid transmission component or the like allows for rapid deploymentand/or replacement of the sensors S to existing pipeline, refinery etc.infrastructure. To this end, the present disclosure sets forth severalattachment structures and configurations to meet the demands of variousinstallations.

Turning to FIGS. 6-8 , three different flexible strap attach assembliesA1, A2 and A3 are shown. It should be appreciated that each assembly A1,A2 and A3 is configured to be wrapped around or otherwise closelyengaged with a portion of a component to be monitored for chemicals ofcorrosion or leaks, or structure adjacent the component to be monitoredfor chemicals of corrosion or leaks. By providing the sensor S as partof these flexible strap attach assemblies, the sensor S can be readilyaffixed to a wide range of infrastructure. Each of the assemblies areshown in schematic partial cross-section to illustrate the variouslayers of each assembly. It should be appreciated that the strap canhave any suitable length. In some examples, the strap can be adjustableand or can include perforations or other part lines to allow the lengthof the strap to be shortened.

In FIG. 6 , the strap attach assembly A1 includes a base layer 60 of amaterial including a hook-and-loop fastener or other releasablesecurable fastener structure (e.g., adjustable clasp or clamp). An outerlayer 62 of durable and/or flexible fabric sandwiches the sensor S withthe base layer 60. The outer layer 62 can be impermeable, or can bewater impermeable but still permit water vapor and/or other gasses topass there through to optimize sensor functionality and protection. Instill other examples, the outer layer 62 is permeable and breathable toan extent necessary for optimal sensor functionality. Regardless of thephysical properties of the outer layer 62, the outer layer 62 and innerlayer 60 support the sensor S there between.

In FIG. 7 , the strap attach assembly A2 is similar to strap attachassembly A1 but includes a foam or sponge layer 66 in which the sensor Sis at least partially enclosed. In other examples, the sensor S can bepositioned between or suspended between a pair of, or multiple, foam orsponge (or any other material that holds liquid) elements. The foam orsponge layer 66 can provide cushioning to the sensor S and can act toabsorb and/or concentrate leaking fluids or the like and allows foroptimal functionality of the sensor. This can help aid in detection bythe sensor S and can provide, in some instances, some amount ofprotection to the sensor S from the leaking fluid and/or other materialsand/or conditions that would otherwise impede the functionality of thesensor.

In FIG. 8 , the strap attach assembly A3 includes a fine mesh base layer70 on which sensor S is supported. The mesh base layer 70 comprises ahighly durable material that is resistant to extreme conditions. Outerlayer 62 and a magnetic mesh layer 72 sandwich the sensor S along withlayer 70. In this exemplary embodiment, the magnetic mesh layer 72 isused to magnetically secure the strap attach assembly A3 to steel pipeor other component. It should be appreciated that the sensor S can beprovided on a magnetic substrate, such as a magnetic disk or puck or thelike, such that it can be readily magnetically secured to a component.In addition to being fixated magnetically, the sensor itself can be madeusing magnetic nanoparticles, which is a class of nanoparticle that canbe manipulated using magnetic fields. Other sensor components can bemade of pulverized magnetic metals and printed magnetic inks, includingthe power source, sensors, electrical circuits and other components ofthe sensor system. One of the several magnetic inks that can be usedincludes neodymium.

FIG. 9 illustrates an exemplary monitoring system in the form of aflange band 100. The flange band 100 includes a main body portion 102which includes a highly durable material that is resistant to extremeconditions and allows for optimal functionality of the sensor S that caninclude a fabric or the like, supporting a sensor array 104 in themanner described above. First and second straps 106 and 108 extend fromthe main body portion 102 and are configured to secure the flange band100 about a pipe flange 120 (or other structure). As noted above,various attachment mechanisms (hook and loop, magnetic, D-rings, clamp,clasp, etc.) can be provided for securing the straps 106 and 108 aboutthe pipe flange 120. In this embodiment, first and second solar cells110 and 112 are also supported on the main body portion 102. The solarcells 110 and 112 can provide main or supplementary power to the sensorarray and/or other components of the monitoring system 100. The flangeband 100 can further provide protection to the flange 120 (or othercomponent) from corrosion or damage from exposure to the environment.

FIG. 10 illustrates an exemplary pipe structure (or basic portion of achemical processing plant or other facility). A flange band 130 is shownseparate from a sensor S. The sensor S will be supported by the flangeband 130 in proximity to a pipe flange or the like for monitoring thesame. As will be appreciated, the sensor S is configured to communicatewith one or more receivers, which in this embodiment include a mobilephone 132 (or wearable device) and/or a laptop 134. FIGS. 11-15illustrate various exemplary flange bands A4-A9 for securing a sensor Sto a component, such as the pipe flanges of FIG. 10 , or otherstructures. The flange band can be made of highly elastic and durablestructured material such as expandable graphite, graphene, compositeparticles, polymers and elastomers capable of fitting a wide range ofpipes, pipe connectors and joints. The flange bands are made of ruggedmaterials that allow them to properly fit a wide range of pipe sizes. Insome embodiments, the flange band has a zipper compartment where thesensor can be deposited for easy access and replacement. The zipperpocket is made of suitable materials and has an operable environmentthat allows the sensor to function at an optimal level.

In some embodiments, the one or more of the following materials can beused for the flange bands (or portions thereof): nanofibers, polymers,elastomers, large macroscopic materials built in a spider-web like,highly expandable and flexible polyimide substrates that is engineeredin a way to allow unique area dilatations. Other possibilities include:microlattice, graphene, self-healing plastic and other highly rugged andpermeable materials.

Turning to FIG. 16 , yet another attachment device A9 is illustrated. Inthis embodiment, the attachment device includes a bonnet 80 of flexibleand/or elastic material in which sensor S is supported. Bonnet 80 can bean impermeable material such as plastic or the like, or can besemi-permeable or fully permeable, or otherwise configured for optimalfunctionality. In some examples, the bonnet can be waterproof but stillallow water vapor to pass through. The attachment device A includes adurable covering AA, a sensor array SA, a power source CC, an indicatorlight DD, an encrypted serial number EE, a foam/sponge layer FF, and anelastic strip HH.

Bonnet 80 is configured to be telescoped over at least a portion of acomponent, such as a valve V or the like. To this end, the bonnet 80includes an elastic or otherwise resilient opening 82. The opening 82can be enlarged to pass over a certain portion of the valve, such as aknob, lever, wheel or other actuator. In one example, the openingincludes an elastic band. In another example, the opening includes adrawstring or other member for drawing the opening tight, but alsoallowing the opening to be enlarged for installation. As will beappreciated, a clamp, clasp or tie can be fastened about the base of thebonnet 80 to secure it to the component being monitored.

The sensor S can be supported by the bonnet 80 as illustrated, or can besupported in any other suitable location by the bonnet 80. The bonnet 80can be configured to trap and/or concentrate any leaking fluids to aidin detection by the sensor S. The bonnet 80 can be constructed oftransparent material to allow indicator lights of the sensor S to beviewed when the bonnet 80 is installed. In some applications, the valveV can continue to be actuated without removal of the bonnet 80therefrom. This can permit detection of leaks in the valve V that onlyoccur when the valve is in a particular state (e.g., fully open,partially open, fully closed). The sensor(s) S can also be embedded orpart of the material by which the bonnet 80 is made constructed. Suchmaterial is most suitable for the functionality of the sensor device inrelation to the operating valve or component size and relatedconditions.

One function of the bonnet (container) is to trap leakage or unwantedemissions from a monitored component for improved detection. To thisend, the bonnet can be coated with certain materials to keep the gas orother leakage contained in the bonnet. The certain materials could beused for both flange bands as well as valve covers (e.g. bonnet).Certain materials that may be absorbent and/or useful for trappingand/or containing leakage of gasses or liquids include tenax, silicagel, coconut charcoal and graphitized carbon black, etc. In otherexamples, cloth made of graphene or nanotubes with embedded sensorelectrodes can be used. In these examples, the flange bands and/or valvebonnets can be made of flexible graphene electrode cloth. At just oneatom thick, graphene is a very thin substance capable of conductingelectricity. It is very flexible and is one of the strongest materials.These properties make graphene well-suited for this application.

Turning to FIG. 17 , another exemplary embodiment of the presentdisclosure is illustrated wherein a sensor S is supported in a mesh sockM or other covering that is draped over a target component, which inthis embodiment includes a gauge 150 and adjacent valves 152 and 154.

In FIG. 18 , a wire padlock tamper evident safety lock 180 includes asensor S in accordance with the present disclosure. As will beappreciated, the safety lock can be used to lock a component, such as avalve 184. The safety lock 180 includes sensor S, but otherwise isidentical to and can be used in the same manner as, any conventionalsafety lock 180.

In FIG. 19 , a sensor S is supported by an independent mount 190 inposition over or under or nearby a pipe flange (or other component) 192.This arrangement can be useful when a direct attach (e.g., flange bandor bonnet, etc.) is impractical or undesirable.

In some application environments, such as refineries and pipelineinfrastructure, the sensor array will be focused mostly on the detectionof benzene, xylene and toluene among other VOCs and HAPs identified bythe EPA. Such chemical may typically be present in these environments atlevels that, although detectable by the sensor array, may not be causefor taking corrective action. As such, the sensor arrays will beconfigured to sample the environments periodically and to reportdetected concentrations of the chemicals periodically. Accordingly, thesystem will require adequate power to perform the periodic testingand/or reporting. In one example, a solar power supply is provided. Thesolar power supply can include one or more photo-voltaic cells and oneor more batteries for storing solar energy for use by the sensors and/orcommunication circuitry. In some embodiments, the solar cells and/orbatteries can be integral with the monitoring system. In this regard,for example, certain portions of the monitoring system can be fittedwith solar cells (e.g., a housing or other enclosure, the bonnet fabric,etc.) In other embodiments, the solar cells and/or batteries can beexternal to the monitoring system (e.g., separate unit located inposition exposed to the sun and electrically coupled to the monitoringsystem. Solar power is particularly well-suited to pipeline applicationshaving remote sensing locations where other power supplies (e.g., linepower) are not practical. Power can also be provided or harvested fromother sources, such as wind, hydro, thermal, wireless, inductive, etc).The system can also have the capability to switch power sources (i.e.internal, external or natural) based on the operational requirements andpower demands.

It should now be appreciated that aspects of the present disclosureovercome many if not all of the shortcomings of manual LDAR programs.For example, with manual sampling done by a human operator there areother factors that have the potential to bias results. There is thepossibility that the human operator did not calibrate the equipmentproperly based on the target piece of equipment. There is thepossibility that the human operator failed to properly sample the targetpiece of equipment. There is also the possibility of sample bias ortemporary high reading based on unusually high pressure in the system.This is a condition that doesn't always prevail. In other words, thereal-time monitoring of the present disclosure can perform constantmonitoring, rather than a snap shot in a moment in time. This gives theplant operator much more information with which to make maintenancedecisions.

The exemplary embodiments have been described with reference to thepreferred embodiments. Obviously, modifications and alterations willoccur to others upon reading and understanding the preceding detaileddescription. It is intended that the exemplary embodiment be construedas including all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof.

The invention claimed is:
 1. A monitoring system for monitoringchemicals in an environment comprising: a sensor including a detectorcomponent operative to generate data in response to the presence orabsence of one or more chemicals or concentration level of one or morechemicals, communication circuitry and a power source operativelycoupled to the detector component and the communication circuitry forsupplying power thereto, the communication circuitry configured totransmit data generated by the detector component to an associatedreceiver; wherein the monitoring system is configured to be placed nearchemical components prone to corrode or near components prone to developunwanted emissions, said components having an interior chamber fortransmitting or storing a fluid or gas; wherein the sensor furtherdetermines at least one of a location or operating status of to thesensor, the communication circuitry configured to transmit at least oneof the location or operating status the associated receiver; and whereinthe detector component includes at least one nanomaterial.
 2. Themonitoring system of claim 1, further comprising at least one inductiondevice for actively or passively directing the unwanted emissionstowards or away from the detector component.
 3. The monitoring system ofclaim 1, wherein the chemical component prone to corrode or developunwanted emissions includes at least one of a fluid or gas extraction,processing, storage or transmission component.
 4. The monitoring systemof claim 3, wherein the component of fluid or gas extraction,processing, storage or transmission includes a pipe flange, and thesensor is further configured to be releasably attachable to anindependent mount near the pipe flange.
 5. The monitoring system ofclaim 4, wherein the sensor is configured to use measurements ofhumidity, temperature and other environmental and chemicalcharacteristics to calibrate the sensor.
 6. The monitoring system ofclaim 1, wherein the chemical component prone to corrode or developunwanted emissions includes a valve, and wherein the monitoring systemfurther comprises a bonnet telescopable over an actuator of the valve.7. The monitoring system of claim 6, wherein the bonnet comprises aflexible material having electrically insulative properties adapted tocover or conform to the outer surface of a valve and to trap one or morechemicals emanating from the valve.
 8. The monitoring system of claim 7,wherein the bonnet is comprised of flexible power source layer, flexibleprinted circuit board layer comprised of communication circuitry and anattachment mechanism for attaching to the detector component.
 9. Themonitoring system of claim 1, wherein the power source includes at leastone of a solar cell or a battery.
 10. The monitoring system of claim 1,wherein the power source includes an antenna configured to receiveenergy wirelessly and supply the received energy to at least one of thedetector component or the communication circuitry.
 11. A method ofmonitoring multiple chemical components prone to corrode or prone todevelop unwanted emissions for unwanted emissions from one or more ofthe components, the method comprising: providing a plurality of sensors,each sensor including: a detector component operative to generate datain response to the presence or absence of one or more chemicals;communication circuitry; and a power source operatively coupled to thedetector component and the communication circuitry for supplying powerthereto, the communication circuitry configured to transmit datagenerated by the detector component to an associated receiver;associating each sensor with a respective component to be monitored;monitoring each component with its associated sensor over a period oftime; and transmitting data generated by each sensor to a receiver;wherein each chemical component has an interior chamber for extracting,processing, transmitting or storing a fluid or gas, and wherein eachsensor is located near a respective chemical component; wherein at leastone of the sensors further determines at least one of a location oroperating status of the sensor, the communication circuitry configuredto transmit at least one of the location or operating status to theassociated receiver; and wherein the detector component comprises atleast one nanomaterial.
 12. The method of claim 11, wherein the chemicalcomponents include at least one of a fluid or gas extracting,processing, transmitting or storage component.
 13. The method of claim12, wherein the chemical component includes a valve, and wherein theassociating the sensor with a chemical component includes configuringthe sensor in a safety lock associated with the respective component.14. The method of claim 13, further comprising actively or passivelyinducing at least a portion of the unwanted emission towards and awayfrom the sensor in the safety lock.
 15. The method of claim 11, furthercomprising securing each sensor in a location near at least onecomponent prone to corrode or near at least one component prone todevelop unwanted emissions.
 16. The method of claim 15, wherein thesensor is configured to releasably secure the to a mount independent ofthe chemical component being monitored.
 17. The method of claim 11,wherein each sensor is configured to sense a concentration of the one ormore chemicals, generate data indicative of the sensed concentration,periodically report a sensed concentration over a period of time andgenerating an alert if the sensed concentration exceeds the thresholdconcentration.
 18. A component for fluid or gas transmission or storagecomprising: an interior chamber for transmitting or storing a fluid orgas; and a sensor including a detector component operative to generatedata in response to the presence or absence of one or more chemicals orconcentration level of one or more chemicals, communication circuitryand a power source operatively coupled to the detector component and thecommunication circuitry for supplying power thereto, the communicationcircuitry configured to transmit data generated by the detectorcomponent to an associated receiver; wherein the sensor furtherdetermines at least one of a location or operating status of the sensor,the communication circuitry configured to transmit at least one of thelocation or operating status to the associated receiver; and wherein thedetector component comprises at least one nanomaterial.
 19. Thecomponent according to claim 18, further comprising at least oneinduction device for actively or passively directing emissions from theinterior chamber towards or away from the detector component.
 20. Thecomponent according to claim 18, wherein the component is one of acontrol device, flow conduit, pipe, pressure fitting, pressure reliefdevice, drain, pump, plug, gauge, connector, compressor, pressurizer,open-ended line, closed-ended line, pipe joint, pipe flange, valve,vent, coupling, seal, wellhead, container, turbine, engine, tubing orother equipment or components subject to leak detection and repairregulations or used for extracting, refining, processing, filtration,distillation, mixing, separation, heating, cooling, fermentation, flow,transmission and insulation.